Precision gearbox assembly machine for residential water meters
Sensors and vision components from Balluff enable automation and ensure greater efficiency and quality
Industry: Specialized mechanical engineering | Customer: Apator Powogaz SA, Poland
Apator Powogaz SA, a market leader in water meter production, faced a significant challenge: the manual assembly of gears was slow, error-prone, and resource-intensive. To meet growing market demand while maintaining quality and efficiency, the company sought a modern, automated solution.
With over 100 years of experience, Apator Powogaz is a globally recognized manufacturer serving more than 60 export markets. Employing 400 professionals and generating an annual revenue of 350 million PLN, the company holds a 50% market share in Poland and 7% across Europe-demonstrating its strength and expertise in the industry.
Situation
The core issue lay in assembling the gear mechanism-a crucial component of the water meters. Over 20 types of gears, some featuring neodymium magnets, needed to be precisely assembled. The task was further complicated by various configurations and designs of dials and disks.
This manual process was labor-intensive, prone to errors, and time-consuming, leading to quality inconsistencies and frequent customer complaints. High labor costs and the demand for faster production cycles and greater precision made the existing method increasingly unsustainable.
Challenge
Apator Powogaz aimed to revolutionize its production process. The goal was to eliminate inefficiencies, reduce errors, lower costs, and drastically cut production times. The company needed an automated assembly solution capable of managing over 70 different gear configurations with absolute precision.
Solution
The Robotics and Automation department at Apator Group developed a cutting-edge automated assembly line tailored to the company's needs. This solution seamlessly combined advanced robotics, smart systems, and precision mechanics:
Index tables and universal sockets: These ensure exact positioning of components, guaranteeing repeatable assembly with high accuracy.
Five industrial robots: Each robot is programmed to execute specific assembly tasks with precision, ensuring perfect alignment and integration of all parts.
Sensors and vision systems: Over 560 sensors and an advanced vision system monitor every stage of the process, detecting and addressing even the smallest deviations in real time.
Laser marking: Each water meter is engraved with a unique serial number, enabling full traceability throughout its lifecycle.
The result? A water meter is now assembled in just 8 seconds, delivering unparalleled efficiency and accuracy.
How it works?
The automated assembly process begins with raw components being transported on dedicated conveyor pallets. A sophisticated vision system by Balluff inspects each part, verifying its position and alignment to ensure it meets strict quality standards.
Next, components are transferred to the index table, where universal sockets ensure precise placement. Industrial robots take over from here, performing various assembly tasks with accuracy and speed. Vibratory feeders deliver additional parts, while the robots systematically position and secure them, ensuring flawless integration.
The process is meticulously monitored by sensors that detect any discrepancies in size, color, or alignment, triggering immediate corrective actions if needed. Once assembly is complete, the water meter is laser-marked with an individual serial number for tracking and quality assurance.
A key highlight: the entire assembly process takes just 8 seconds per unit. The synchronized operation of robots and conveyors ensures a seamless and efficient production flow.
With its new automated assembly line, Apator Powogaz has set a benchmark in water meter production. By reducing production times, ensuring precision, and enhancing flexibility, the company has solidified its position as a market leader. This innovation highlights how advanced technology can transform manufacturing processes and provide a competitive edge in a demanding market.
Benefits
The implementation of this automated system brought transformative results for Apator Powogaz:
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Error elimination and quality improvementAdvanced robotics and continuous monitoring drastically reduced production defects and customer complaints.
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Cost savings:Automation reduced the reliance on manual labor, significantly cutting production costs.
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Speed and efficiency:The drastically reduced assembly time and 24/7 operational capacity allowed the company to meet increasing demand with ease.
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Flexibility:The system's adaptability enables quick reconfiguration for different water meter types, allowing Apator Powogaz to respond swiftly to market changes.
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Comprehensive quality control:Integrated sensors ensure that only flawless products leave the production line, securing customer satisfaction and loyalty.
Products
A vision system based on the BVS CA-SF2-0032AG USB 3.0 cameras with a resolution of 3.2 MPixel is used to identify the positions of the water meter blank and to check the correct gearing and position of the gearbox at the end of assembly. Other components are used for communication, for feeding and determining the position of components and robots, etc. The following list is only an excerpt of the most frequently used sensors.